SANYO DENKI Technical Report No.6 Nov. 1998

New Products Introduction

Development of Industrial PC "SMAC-PC" and

"S-MAC" Components

Shigeki Satou Hiroshi Okino Hiroshi Yoshikawa

1. Introduction

Following the "FA open architecture declaration" in November 1996, we have

developed "S-MAC" system to provide a FA total solution. In June 1998, we started

receiving orders. In order to optimize "S-MAC" system, we have also started

developing the main components as well. To promote the open architecture, we

have been marketing the main components of "S-MAC" system since October 1998.

This paper introduces the development concept of "S-MAC" components and the

key components of Industrial PC "S-MAC PC" system. "SMS-10" of "S-MAC PC"

series is explained in some detail along with some specific examples of application.

2. "S-MAC" Components

In general, an FA intelligent system requires the components or elements marked

to in the hierarchy shown in Fig. 2.1.

Sanyo Denki has developed various components providing a total solution to

facilitate the integration of customers' systems.

To create an FA intelligent system, the 4th and 5th levels of the CIM hierarchy

mainly utilize:

factory control systems such as production control systems

assistant software for shop layer control, especially languages for motion

description and sequence description

while the 2nd and 3rd levels mainly utilize:

industrial personal computers (PCs) for real-time operations

software or firmware capable of real-time operations such as motion cards and

motion software

the 1st and 2nd levels mainly utilize:

open (hardware and software) communication interfaces for motion networks

various drivers supporting motion networks, such as SERCOS and DeviceNet

various motors and sensors (rotation type or linear type) connected to the open

architecture drivers

In the remainder of this section, we introduce the specific products corresponding

to each of Sanyo Denki's "S-MAC" components.

Component products are customer-specific and thus will not be covered in this

paper.

Component products are mainly:

(a) object-oriented (such as electronic shaft and electronic cam) synchronizing

control motion language, AML, for which both development and runtime are

available (see Fig. 2.2)

(b) The "Code System" used to develop robots, using 3D simulation programs

Component products are so-called FA PCs. Sanyo Denki has individually

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developed "S-MAC PC" series as a part of "S-MAC" components. "SMS-10" model

(see Fig. 2.3) can be installed with SERCOS execution routines as a standard

feature. Sections 3 and 4 discuss the features and applications of "SMS-10".

Component products are motion control circuit boards available from various

manufacturers. "SMS-10", which can be installed with "AML" execution routines

("AMS" runtimes), does not require this circuit board because the corresponding

function is provided by software.

Component products of Sanyo Denki currently support SERCOS and DeviceNet

of the open motion networks. Especially for SERCOS, three types of

communication interface cards (see Fig. 2.4) are available (PC/104 type, PC-AT1/2

type and PCI type).

A component product had already been on the market as a driver with open

network support (see Fig. 2.6). We have added this product to "S-MAC" series

while developing new "PQ" multi-axis AC amplifiers (see Fig. 2.5)to make

"S-MAC" components even more complete. This environment simplifies the process

of system integration for customers while allowing the customers to choose between

products, thus leading to truly open architecture systems.

Furthermore, "PQ" series supports DI/DO as a standard feature, thus greatly

simplifying the system configuration in cooperation with the PLC function of

"AML" software.

As for DeviceNet, drivers such as "PU", "PM" and "ROBUSTSYN" have been

developed, allowing customers to choose between motors more freely (see Fig. 2.7).

As component products, we are planning to add "S" series and "Hyperlinear"

series motors to "S-MAC" components in addition to "P" series motors, thus

increasing the number of possible configurations (see Fig. 2.8).

Fig. 2.9 illustrates where "S-MAC" components fit into an actual FA intelligent

system.

As shown in Fig. 2.10, "S-MAC" components are designed to connect with the

upper layer, the lower layer and the same-level layer in the hierarchy. This design

eliminates redundancy in the system without restricting choice, thus optimizing the

system without compromising freedom of choice.

3. Development of Industrial PC "S-MAC PC"

3.1 Concepts in developing "S-MAC PC"

The concept in developing "S-MAC PC" is clear from its market position

illustrated in Fig. 3.1. "S-MAC PC" is an industrial personal computer (PC) whose

environment resistance characteristics have been improved without compromising

its low costs, by limiting its functions to use only as "S-MAC" components. Limiting

its functions does not mean loss of flexibility, as shown in Fig 3.2. Due to its

improved network communication interface with the upper and lower layers, its

range of application is broader than that of general-purpose FA PCs.

The software functions installed in each of the cases A to H are listed below. More

specific cases of systems will be discussed in the following section.

A. Full-software controller

when "AML" execution routines are installed (use as "S-MAC" Type C target

PC)

B. PC NC

when a PC104-type motion card is installed

C. DeviceNet master

when a DeviceNet communication I/F is installed

D. PC PLC

when software PLCs such as ISaGRAF are installed

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E. Cell controller

when used as an FMS or FMC controller

F. Image processing

when image processing control software is installed

G. Measurements using PC

when an A/D conversion board and data acquisition software are installed

H. Control using PC

when used as a process control PC taking advantage of its real-time processing

abilities

I. Dedicated 3D Controller

when the CODE system is installed (used as "S-MAC" Type A target PC)

We have developed "SMS-10" as a part of "S-MAC PC" series, which will be

discussed in the following subsection.

3.2 "SMS-10" Basic Configuration

3.2.1 Hardware

Fig. 3.3 illustrates an example of the configuration of "SMS-10".

We have avoided using parts with rotating mechanisms in "SMS-10", opting for

vibration- and shock-resistant CompactFlash instead of a hard disk, while the CPU

is naturally cooled only by a heat sink.

Reliability has been further improved by such functions as a watchdog timer and

optional error-free memory, referred to as Reliability, Availability, Serviceability

(RAS) functions.

As a networking environment, an Ethernet interface is provided as standard, while

PC/104 module interfaces are provided as standard to connect to other networks.

With an optional PCMCIA module, various PC cards can be used.

The outline of each configuration parts are listed below.

(a) CPU module (see Fig. 3.4)

(1) Ethernet interface (NE2000 compatible) on-board

(2) upgradable to 32MB EDO DRAM

supports error-free memory

(3) IDE hard disk interface on-board

(4) 2 serial interface ports

(RS-232/422/485 x 1ch, RS-232 x 1ch)

(5) digital I/O (4 inputs, 4 outputs, TTL compatible)

(6) PC/AT compatible keyboard interface

(7) 5V single power source

(b) RAS module (see Fig. 3.5)

(1) PC/104 interface expansion connector on-board

(2) watchdog timer circuit on-board

(3) digital I/O (2 isolated inputs, 2 isolated outputs)

(c) SERCOS I/F module (see Fig. 3.6)

(1) optical fiber interface conforming with IEC61491 (SERCOS) standard

(2) 2Mbps or 4Mbps communication rate

(d) PCMCIA module (see Fig. 3.7)

(1) conforms with PCMCIA v. 2.10 and JEIDA v. 4.1

(2) can contain two Type I/II PC cards or one Type III PC card

(e) Encoder module (see Fig. 3.8)

(1) counter for 32-bit encoder on-board

(2) 90-degree phase A/B signal

connected with line driver or open collector

(3) digital I/O

position latch signal, 4 isolated inputs, 4 isolated outputs

(f) DI/DO module (see Fig. 3.9)

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(1) 24 inputs and outputs, TTL compatible

(2) simulates 8255PPI mode (port C0 cannot be separated)

(g) VGA module (see Fig. 3.10)

(1) CHIPS65535 chip

(2) VGA (640x480 pixels) 256 colors

(h) DeviceNet module (see Fig. 3.11)

(1) 5-pin CAN connector (DeviceNet compatible)

(2) network status 2-color LED

(3) 16KB shared memory on-board (for interface with the host)

(4) 125K, 250K, 500Kbps transfer rates

(i) Motion module (see Fig 3.12)

(1) optical fiber interface conforming with IEC61491 (SERCOS) standard

(2) 2Mbps or 4Mbps communication rate

(3) DSP for motion control on-board

(4) C programming environment with C function library (over 250 types)

available

(j) Storage device (see Fig. 3.13)

(1) CompactFlash (15 to 45MB) or HDD (2.5" IDE Harddisk)

3.2.2 "SMS-10" Basic Specifications

Table 3.1 illustrates the basic specifications of "SMS-10". Table 3.2 illustrates the

general specifications of "SMS-10".

3.2.3 Software

Because "S-MAC PC" is functionally PC/AT compatible, various applications are

possible. It is also a key component of Sanyo Denki's total solution when used as a

runtime application of AML (for details, see SANYO DENKI Technical Report No.

5, May-1998, Harada et al., "Application of S-MAC TYPE C").

AML is an application for iRMX (Radysis RTOS). Therefore, the "iRMX version"

allows use of AML.

A VxWorks version and WindowsNT version are also available, because AML is

currently being modified to run on both VxWorks (WindRiver RTOS) and

RTX/WindowsNT (VentureCom RTOS).

3.2.4 Panel Example

Fig. 3.14 illustrates an example of the panel layout on "SMS-10". In this case, the

panel contains the CPU, RAS, PCMCIA, SERCOS I/F, Encoder, DI/DO and VGA

modules.

4. Application Examples of "S-MAC PC"

4.1 Application to Food Packaging Machine

In Fig. 4.1, "S-MAC PC" is applied to a food packaging machine as an FA

intelligent system.

"S-MAC PC" executes a program written in the AML control language to act as a

device controller. It is connected to the servo amplifier via the SERCOS network.

To exchange simple parameters, a commercially-available intelligent display is

connected via RS-232C as a human machine interface (HMI). Since "S-MAC PC"

comes standard with an Ethernet interface, connection to LAN is simple. A LAN

connection may be used for such tasks as production control.

4.2 Application to Printing Machine

In Fig. 4.2, "S-MAC PC" is applied to a printing machine.

"S-MAC PC" executes a program written using the AML control language to act

as a device controller. To exchange complex parameters and data, a commercially-

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available panel computer is connected via RS-232C as an HMI. The LAN is

accessible through the panel computer and may be used for such tasks as production

control.

4.3 Application to Wire Winding Machine

In Fig. 4.3, "S-MAC PC" is applied to a wire winding machine.

In this case, two "S-MAC PCs" are utilized, one executes a program written in the

AML control language to act as a device controller, and the other acts as an HMI

controller. The HMI "S-MAC PC" has a VGA to display information on the panel

display. By using two "S-MAC PCs" the system does not need a hard disk.

5. Conclusion

In this paper, we have discussed various key elements in creating an FA intelligent

system, focusing on Sanyo Denki's product groups. "S-MAC PC", a key component

in "S-MAC" components, has been described in detail along with detailed

specifications and applications of "SMS-10".

Because the architecture of each component is open, our components may be

utilized in combination with products from other domestic or overseas

manufacturers. We hope this paper will help customers develop their systems.

* Names of companies, products, and registered trade marks are those of the respective companies.

Shigeki Satou

Joined company in 1984.

Servo Systems Division, Control System Dept.

Worked on the development of the S-MAC system.

Hiroshi Okino

Joined company in 1996.

Servo Systems Division, Control System Dept.

Worked on the development of controllers.

Hiroshi Yoshikawa

Joined company in 1996.

Servo Systems Division, Control System Dept.

Worked on the development of controllers.

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Fig. 2.1 CIM hierarchy and "S-MAC" components

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Fig. 2.2 "AML" full-software control language

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Fig. 2.3 Industrial PC "S-MAC PC"

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Fig. 2.4 SERCOS interface cards

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Fig. 2.5 Multi-axis servo amplifier, "PQ" series

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Fig. 2.6 "PZ" amplifier with SERCOS support

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Fig. 2.7 Amplifiers with DeviceNet support

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Fig. 2.8 Servo motors and sensors

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Fig. 2.9 Example of installation in an actual system

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Fig. 2.10 Design concept of "S-MAC" components (for "S-MAC PC")

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Table 3.1 Basic specifications of "SMS-10"

Basic specifications

CPU Am5x86-P75/133MHz

BIOS made by AWARD

Main memory 16MB to 32MB

72-pin SIMM socket 1

error-free memory (optional)

Storage CompactFlash (15MB to 45MB)

HDD (optional)

Serial COM1:RS-232 1

COM2:RS-232/422/485 1

Keyboard MINI DIN 6-pin

Ethernet 10Base-T (RJ-45)

Chipset: Realtek RTL8019

I/O 4 inputs, 4 outputs (TTL compatible)

2 insulated inputs, 2 insulated outputs

Expansion interface PC/104 interface (up to 5 modules)

RAS functions watchdog timer,etc.

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Table 3.2 General specifications of "SMS-10"

General specifications

Voltage requirement DC4.75 to 5.25V

Temperature 0 to 50 (operating)

-10 to 60 (non-operating)

Humidity 20 to 90% (operating, no condensation)

90% or less (non-operating, no condensation)

Vibration 4.9m/s2 (operating) 9.8m/s2 (non-operating)

Shock 98m/s2 (non-operating)

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Fig. 3.1 Product position

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Fig. 3.2 Application examples

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Fig. 3.3 Example of "SMS-10" configuration

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Fig. 3.4 External appearance of CPU module

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Fig. 3.5 External appearance of RAS module

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Fig. 3.6 External appearance of SERCOS I/F module

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Fig. 3.7 External appearance of PCMCIA module

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Fig. 3.8 External appearance of Encoder module

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Fig. 3.9 External appearance of DI/DO module

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Fig. 3.10 External appearance of VGA module

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Fig. 3.11 External appearance of DeviceNet module

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Fig. 3.12 External appearance of motion module

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Fig. 3.13 External appearance of storage devices

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Fig. 3.14 Example of panel layout on "SMS-10"

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Fig. 4.1 Example of applying "S-MAC PC" to packaging machine

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Fig. 4.2 Example of applying "S-MAC PC" to printing machine

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Fig. 4.3 Example of applying "S-MAC PC" to wire winding machine

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